Reflective-fibrous type insulation



Aug. 29, 1961 w. T. TlLLo-rsoN REFLECTIVEFIBR0US TYPE INSULATION FiledJune 7, 1957 l'United States Patent i assignments, to United StatesGypsum Company, Chicago, Ill., a corporation of Illinois Filed June 7,1957, Ser. No. 664,196 4 Claims. (Cl. 154-44) The present inventionrelates to a novel reflectivefibrous type insulation in which a brousinsulating material such as batt of mineral wool, is provided on itsopposite sides or exposed surfaces with a sheet of reflective material,such as aluminum or other metal foil.

When reflective surface material or metal foil is applied as a coveringfor the sides and edges of a batt or fibrous insulation, such coveringprovides a continuous metallic link from the warmside to the cold sideof the insulation whereby heat transfer through the metallic coveringsubstantially diminishes the insulating properties of the assembledunit. Furthermore, extending the metallic surface material over andalong the edges of the assembled unit performs no useful function,interferes with the successful compression packaging of these insulationunits and may prevent their return to their original thickness.

By means of the present invention a continuous metallic link from thewarm side to the cold side is eliminated and the novel assemblyincreases the insulating properties of the composite unit. In addition,it reduces the cost of the composite assembly in that it reduces thequantity of metallic reectivesurface material required, promotessuccessful compression packaging of these units to decrease their bulkand aids return of the compressed composite units to their originalthickness.

It is, therefore, an important object of the present invention toprovide a novel composite insulation unit having a sheet or strip ofmetal foil providing a reflective surface material on its exposedsurfaces only with the metal foil providing one exposed surface beingimperforate to form a vapor barrier that prevents the passage ofmoisture and the other sheet or strip of metal foil providing the otherexposed surface being perforated to provide a permeable membrane thatpermits the escape of any entrapped moisture that may have collected orobtained access to the interior of the insulating unit.

Another important object of the present invention is the provision of anovel insulating unit comprising a batt of insulating material, such asmineral wool, and a novel covering or envelope encompassing the batt,such covering or envelope comprising a sheet of retaining paperoverlying onel surface or side of and overlapping the opposite edges ofthe batt and to the exterior of this paper is superimposed and aixed asheet of perforated metal foil providing an exposed surface, and a sheetof imperforate metal foil overlying the opposite surface or side of thebatt and joined to the opposite edges of the retaining paper, the latterproviding the other exposed surface of the insulating unit.

A further object of the present invention is the provision of anovelmeans and manner of forming an insulating unit including a batt offibrous insulating material and an encompassing covering for the batt,said covering having a strip of metal foil or reflective surfacematerial providing the opposite expo-sed surfaces Patented Aug. 29, 19612 of the unit, with the opposite edges of the unit being devoid of anymetallic link between the strips of metal foil.

Further objects are to provide a construction of maximum simplicity,eciency, economy and ease of assembly and operation, and such furtherobjects, advantages and capabilities as will later more Ifully appearand are inherently possessed thereby.

In the drawing:

FIGURE 1 is a view in perspective of the novel composite insulating unitof the present invention, but with a portion of the overlying orexternal sheet of metal foil on one face having been broken away.

FIG. 2 is an enlarged fragmentary view in vertical cross section takenlongitudinally through the insulating unit in a plane represented by theline 2 2 of FIG. 1 and viewed in the direction of the arrows.

FIG. 3 is an enlarged fragmentary vertical cross-sec.- tional Viewthrough the insulating unit but taken in a plane represented by the line3--3- of FIG. l and viewed in the direction of the arrows.

FIG. 4 is a top plan view but on a reduced scale from that in FIGS. 1, 2and 3 of the sheet of retaining paper and its overlying strip ofperforated metal foil extending longitudinally and substantiallycentrally of and afiixed to the paper, a portion of the strip of metalfoil having been removed to show the underlying sheet of paper.

FIG. 5 is a top plan view but also on a reduced scale of the imperforatesheet of metal foil to which has been applied a coating of asphalt.

Referring to the disclosure in the drawing and to the illustrativeembodiment disclosed therein, the novel insulation unit consists of asuitable thickness of fibrous insulation material, such as a batt ofmineral wool 11, having a covering or envelope 12 encompassing the battand comprising a sheet of retaining paper 13 to which is affixed acentrally arranged and longitudinally extending strip of perforatedmetal Ifoil or reflective material 14, such as aluminum foil,superimposed on the upper or outer surface of the paper.

'Ihe strip of metal foil 14 which is centrally disposed upon the sheetof retaining paper 13 and adhesively joined thereto is of a width tocompletely overlie one face or side of the batt of insulation and extendover the longitudinal corners as shown in FIG. 3, with the spacedexposed portions 15 of this paper sheet overlapping and covering theopposite edges of the batt 11, the longitudinal edges of the paperproviding an external flange 16 at each side thereof.

By retaining the outer edges of the strip of metal foil 14 imperforateand unbroken, these imperforate edges provide for greater strength,surface adhesion and retention of the metal foil 14 upon the underlyingsheet of retaining paper 13, and resist fraying or tearing along theseedges during manufacture and use.

The other side of the batt (shown as the lower or inner surface in thedrawings) is covered by a sheet of imperforate metal foil or reflectivematerial J17 having a coating of asphalt 18 applied to one face thereofover its entire length and width, the width being substantially greaterthan the width of the batt of insulation 11 with the edges 19 thereofadapted to overlap the external flanges 16 of the retaining paper 13.When the edges 19 are bent over the flanges 16 to form the overlap,pressure applied to the overlap adhesively joins these edges and flangesand provides an effective seal.

These composite insulation units with the envelope or covering 12extending for the full length of the batt are of substantial dimensionsfor providing insulation in the ceiling, side walls and/or flooring ofan enclosure or building. When assembled, the side of the units with thesheet or strip of imperforate metal foil 17 exposed faces the interiorof the enclosure so as to provide a vapor barrier against the passage ofmoisture to the walls, ceiling or floor. The other or outer exposed faceof these insulating units is covered by the sheet or strip of perforatedmetal foil 14 to permit the escape of moisture or condensate that mightcollect.

As one example and for ease in packaging land use, these insulatingunits may be approximately 15 inches wide, approximately 3 inches thickand may be in units having a length approximately 24 inches, 48 inchesor greater, although these measurements are intended merely asillustrative and not as a limitation of the present invention. Theopposite ends `2l of the insulating batt 11 are not enclosed by thecovering or envelope.

As the sheets or strips of metal foil 14 and 17 do not encompass orcover the opposite edges 22 of the novel insulating units which arecovered only by the sheet of retaining paper, there is no metallic linkor conduction from the warm side to the cold side of the unit so that aminimum heat transfer is effected. Furthermore, as these opposite edges22 are not covered or enclosed by the metal foil, the units soconstructed and assembled may be successfully compression packaged and,when removed from the package for use, automatically return to theiroriginal dimensions or thickness. It will be further apprecated that byretaining these edges uncovered by the metal foil, there is asubstantial saving in such metal foil.

The novel insulating unit of the present invention is effective duringwinter when the heat flottI is up and out of a building or enclosure,and when the heat flow is down as occurs during the hot summer weather.The metal foil or reflective surface material is particularly effectivewhen the heat flow is down and supplements the protection yafforded bythe fibrous insulation for use with air conditioning or artificialcooling. As there is no metallic link or heat conduction from the warmto the cold side, the insulation value of the present assembly isincreased.

Having thus disclosed the invention, I claim:

l. A resiliently compressible insulating unit for providing insulationto a building structure surface consisting of a compressible batt ofinsulating material; and an envelope for enclosing thenormally-outer-facing and normally-inner-facing surfaces and twolaterally opposed sides of said compressible batt, said envelopeconsisting of a paper sheet substantially completely covering saidnormally-outer-facing and two laterally opposed sides of said batt andextending from said sides adjacent the normally-inner-facing surface ofsaid batt to form a pair of flanges, an imperforate metal foil sheetaffixed to and substantially completely covering thenormallyinner-facing surface of said batt, the lateral edge portions ofsaid imperforate metal foil sheet being affixed to said flanges of saidpaper sheet, a strip of perforate metal foil aflixed to andsubstantially conterminous with the portion of said paper sheet coveringsaid normally-outer-facing surface, said perforate metal foil providinga heat-reflective surface and permeable membrane for the escape ofmoisture vapor entrapped in said batt, andthe portions of said papersheet covering the laterally opposed sides of said batt beingsubstantially free and uncoveredy by said metal foil sheets, wherebythere is no contact between said perforate and imperforate `foil sheets.

2. A resiliently compressible insulating unit for providing insulationto a building structure surface consisting of a compressible batt offibrous insulation; and an envelope for enclosing thenormally-outer-facing and normally-inner-facing surfaces and twolaterally opposed sides of said compressible batt, said envelopeconsisting of a paper sheet substantially completely covering saidnormally-outer-facing surface and two laterally opposed sides of saidbatt and extending from said sides adjacent the normally-inner-facingsurface of said batt to form a pair of flanges, an imperforate metalfoil sheet adhesively aflixed to and substantially `completely coveringthe normally-inner-facing surface of said batt, the lateral edgeportions of said imperforate metal foil sheet being affixed to saidflanges of said paper sheet, a strip of perforate metal foil affixed toand substantially conterminous with the portion of said paper sheetcovering said normally-outer-facing surface, said perforate metalproviding a heat-reflective surface and permeable membrane yfor theescape of moisture vapor entrapperd in said batt, and the portions ofsaid paper sheet covering the laterally opposed sides of said batt beingsubstantially free and uncovered by said metal foil sheets, wherebythere is no contact between said perforate and imperforate foil sheets.

3. A resiliently compressible insulating unit for providing insulationto a building structure surface consisting of a compressible batt offibrous insulation; and an envelope for enclosing thenormally-outer-facing and normally inner-facing surfaces and twolaterally opposed sides of said compressible batt, said envelopeconsisting of a paper sheet substantially completely covering saidnormally-outer-facing surface and two laterally opposed sides of saidbatt and extending from said sides adjacent the normally-inner-facingsurface of said batt to form a pair of flanges, an imperforate metalfoil sheet adhesively affixed to and substantially completely coveringthe normally-inner-facing surface of said batt, the lateral ed-geportions of said inperforate metal foil sheet being adhesively affixedto said flanges of said paper sheet, a strip of perforate metal foilaffixed to and substantially conterminous with the portion of said papersheet covering said normally-outer-facing surface, said perforate metalfoil being devoid of perforations in the lateral portions adjacent thejuncture of said normally-outeryfacing surface and the side surfaces toprovide for greater strength and surface retention of said lateralportions of said perforate metal foil to the paper sheet and to resistfraying and tearing along said lateral portions of said perforate metalfoil, said perforate metal foil providing a heat reflective surface andpermeable membrane adapted to permit the escape of moisture vaporentrapped in said batt, and the portions of said paper sheet coveringthe laterally opposed sides of said batt being substantially free anduncovered by said metal foil sheets, whereby there is no contact betweensaid perforate and imperforate foil sheets.

4. A resiliently compressible insulating unit for providing insulationto a building structure surface consisting of a compressible batt offibrous insulation; and an envelope for enclosing thenormally-outer-facing and normally-inner-facing surfaces and twolaterally opposed sides of said compressible batt, said envelopeconsisting of a paper sheet substantially completely covering saidnormally-outer-facing surface and two laterally opposed sides of saidbatt and extending from said sides adjacent the normally-inner-facingsurface of said batt to form a pair of flanges, a sheet of imperforatemetal foil having a coating of asphalt on one surface thereof, whichsurface is adhesively affixed to and covers the normally-innerfacingsurface of said batt and is in overlapping and sealed relationship tosaid flanges, a strip of perforate metal foil alixed to andsubstantially conterminous with the portion of said paper sheet coveringsaid normally-outerfacing surface, said perforate metal foil beingdevoid of perforations in the lateral portions adjacent the juncture ofsaid normally-outer-facing surface and the side surfaces to provide forgreater strength yand surface retention of said lateral portions of saidperforate metal `foil to the paper sheet and to resist fraying andtearing along said lateral portions of said perforate metal foil, saidperforate metal foil providing a heat reflective surface and permeablemembrane adapted to permit the escape of moisture vapor entrapped insaid batt, and the portions of said paper sheet covering the laterallyopposed sides of said ybatt being substantially free and uncovered byReferences Cited in the iile of this patent said metal foil sheets,whereby there is no contact be- 10 2,757,116

tween said perforate and imperforate foil sheets.

UNITED STATES PATENTS Roos June 13, 1933 Benedict Dec. 14, 1937 SchenkMar. 5, 1940 Grassick Mar. 2, 1943 Russum Nov. 27, 1951 Lemmerman Apr.6, 1954 Clements July 31, 1956 UNITED STATES PATENT OEEICE CERTIFICATEOF CORRECTION Patent No?. 2,998,337 l August 29V 1961 Wesley T.Tillotson It is hereby certified that error appears in the abovenumbered patentrequiring correction and that the said Letters Patentshould read as 'corrected below.

Column 3, line 35, for "apprecated" read appreciated column 4L, line I6,after "metal" insert foil line 189 for "entrapperd" read entrapped line27, after "normally", second occurrence, insert a hyphen.

Signed and sealed this 13th day of February 1962.

C SEA L) Attest:

ERNEST w. VSWIDEE Attesting Officer DAVID L. LADD Commissioner ofPatents

1. A RESILIENTLY COMPRESSIBLE INSULATING UNIT FOR PROVIDING INSULATIONTO A BUILDING STRUCTURE SURFACE CONSISTING OF A COMPRESSIBLE BATT OFINSULATING MATERIAL; AND AN ENVELOPE FOR ENCLOSING THENORMALLY-OUTER-FACING AND NORMALLY-INNER-FACING SURFACES AND TWOLATERALLY OPPOSED SIDES OF SAID COMPRESSIBLE BATT, SAID ENVELOPECONSISTING OF A PAPER SHEET SUBSTANTIALLY COMPLETELY COVERING SAIDNORMALLY-OUTER-FACING AND TWO LATERALLY OPPOSED SIDES OF SAID BATT ANDEXTENDING FROM SAID SIDES ADJACENT THE NORMALLY-INNER-FACING SURFACE OFSAID BATT TO FORM A PAIR OF FLANGES, AN IMPERFORATE METAL FOIL SHEETAFFIXED TO AND SUBSTANTIALLY COMPLETELY COVERING THENORMALLYINNER-FACING SURFACE OF SAID BATT, THE LATERAL EDGE PORTIONS OFSAID IMPERFORATE METAL FOIL SHEET BEING AFFIXED TO SAID FLANGES OF SAIDPAPER SHEET, A STRIP OF PERFORATE METAL FOIL AFFIXED TO ANDSUBSTANTIALLY CONTERMINOUS WITH THE PORTION OF SAID PAPER SHEET COVERINGSAID NORMALLY-OUTER-FACING SURFACE, SAID PERFORATE METAL FOIL PROVIDINGA HEAT-REFLECTIVE SURFACE AND PERMEABLE MEMBRANE FOR THE ESCAPE OFMOISTURE VAPOR ENTRAPPED IN SAID BATT, AND THE PORTIONS OF SAID PAPERSHEET COVERING THE LATERALLY OPPOSED SIDES OF SAID BATT BEINGSUBSTANTIALLY FREE AND UNCOVERED BY SAID METAL FOIL SHEETS, WHEREBYTHERE IS NO CONTACT BETWEEN SAID PERFORATE AND IMPERFORATE FOIL SHEETS.